Web joiner



G. R. NOEL WEB JOINER Nov. 15, 1966 Filed Feb. 24, 1964 Sheets-Sheet 1v/ Z i d M k IIIIIIIIIIII/ \j/ I 3/ g k3 (3 INVENTOR 1 (\l i GEORGE R.NOEL M k). m

ATTORNEY Nov. 15, 1966 G. R. NOEL 3,284,873

WEB JOINER Filed Feb. 24, 1964 4 Sheets-Sheet 2 I INVENTOR. F 5 GEORGER. NOEL M a]. m

ATTORNEY G. R. NOEL WEB JOINER Nov. 15, 1966 4 Sheets-Sheet 5 Filed Feb.24, 1964 INVENTOR.

GEORGE R. NOEL M ATTORNEY United States Patent 3,234,873 WEB JOINERGeorge R. Noel, North 'Wales, Pa., assignor t0 Pennsalt ChemicalsCorporation, Philadelphia, Pa., a corporation of Pennsylvania Filed Feb.24-, 1964, Ser. No. 346,858 13 Claims. (Cl. 29-21.1)

This invention relates to web joining apparatus or web joiners orsplicers, as they are commonly called. More particularly it relates tosplicers for joining metal sheets in a sheet metal treating line ofequipment while the sheets are continuously being introduced into theline from a supply station.

A general object of the invention is to permit the leading portion of anew web, i.e. a metal sheet, which initially is substantially stationaryto be joined or spliced to the trailing portion of a preceding web whichis moving without shutting down or slowing down the line.

The cleaning, corrosion treating, tinning, annealing, plating, paintingand other surface finishing operations on various kinds of metal sheetmaterial is carried out in modern treating lines at rates of severalhundred feet per minute. Shutting down of the line to charge new sheetsis undesirable and costly. Difiiculties also arise when the end of onepiece of material is reached and a new piece of material must be startedinto the line and be guided through the various intricacies of thevarious pieces of equipment which are generally installed in a treatingline. In order to avoid these difficulties, and to avoid shutting down,it is desirable to join the end of an expiring piece of material to thebeginning of the next piece preferably without stopping or slowing downthe line. When the ma terial is ordinary steel, welding can be resortedto if the metal is sufficiently thick. And if the metal is copper orbrass, brazing may be used. Aluminum welding also can be carried out onalum'mum sheet. However, on thin material, e.g. foils, and onnon-metallics, these fusion methods of joining are impractical.Furthermore, material flow must stop.

The web joiner and method hereinafter described do not depend on suchfusion methods and permit the mechanical joining of two or more sheetsof web, each sheet ranging in thickness from about 0.004 inch to about0.065 inch, in an instant while the sheets move from a supply stationand through the web joiner at a lineal speed of 200 feet or more perminute.

The web joiner of this invention uses a plurality of cutting projectionsmounted on the periphery of a moving arcuate surface and cooperatingwith an opposed slotted die plate to shear tabs through and to the rearof the surfaces of interlying, moving overlapped webs movingco-directionally with said arcuate surface and at the same velocity. Inthe preferred embodiment shown herein, it is essential that the startingor leading end of the second sheet lies on top of the tail or trailingend of the first, or preceding, sheet. The tabs are next bent and foldedrearward by foldover means and then are firmly compressed together andagainst the bottom side of the lower web by pressing means. The foldedtabs of the second sheet form recesses within which the tabs of thefirst sheet are folded. As the first sheet 'moves forward through thejoiner and into the treating line, the folded tabs of the first sheetengage the folded tabs of the second sheet in a tightly locked manner sothat the second sheet is pulled forward by the movement of the firstsheet and the tight joints.

Particularly, the web joining machine comprises a tab cutting station, atab folding station and a tab pressing station. The cutting stationconsists of an arcuate toothed section moving co-directionally with thewebs at the same 3,284,873 Patented Nov. 15, 1966 velocity as the websand positioned on one side of the webs, and a corresponding stationarytooth receiving section positioned in tab forming relationship oppositesaid toothed section on the opposite side of said webs. The toothedsection is formed to drive a plurality of tabs outward and rearward fromthe webs so that the tabs project into the tooth receiving section. Thetab folding station consists of a web release and holddown plate and atab knockover plate between which the projecting tabs pass and arefolded rearwardly preparatory to the pressing step. The pressing stationincludes a pressing section on either side of the webs. The pressingsections cooperate with each other to press the folded tabs against thewebs to produce a smooth, tight joint.

More particularly, the cutting station consists of a punch rollpositioned opposite a slotted die plate between both of which the webspass. The punch roll has on its surface a plurality of substantiallyhexahedral, e.g. cube shaped, cutting projections, hereinafter referredto as teeth. The teeth are spaced in irregular rows extending along thelength of the roll and in aligned peripheral rows extending part wayaround the periphery of the roll. Each peripheral row of teethessentially has a non-toothed section along an arc of from about to Thenon-toothed sections of the peripheral rows essentially are alignedrelative to each other along the roll so that no tooth on the rollcontacts the webs when the center line along the roll of the arcuatesurface formed by the aligned non-toothed sections is opposite the webs.

Each tooth has forward and side cutting edges and a non-cutting rearwardedge. The teeth are shaped as to width, height and length, so that theset of overlapped tabs which is formed by each tooth as it shears theoverlapped sheets will be long enough to provide sufiicient metal toform a strong overlapped backfold and wide enough so that a minimumnumber of tabs need be formed across the width of the sheets to obtainstrong joints, but yet not so wide that the tabs will be too diflicultto bend over, fold and press in the subsequent steps of the operation.

The height of the teeth must be sutficient to permit each tooth topenetrate through the overlapped sheets and to permit the crown and therear edge of the tooth, as the sides of the tooth shear the sides ofeach set of tabs, to impinge against the topmost tab and depress the setof overlapped tabs below the lower surface of the lower sheet and toforce the tabs downward adequately so that the projecting tabs can becaught and further be folded rearward by a knockover bar or platepositioned between the cutting and pressing stations. The sides of eachtooth are set vertically at right angles to the axis of the punch rolland with their opposite planes substantially parallel to each other. Thecontour of the cutting edge on the face of the tooth, i.e., the front ofthe tooth relative to the direction of movement, is not critical. Asquare edge is preferred. The height of each tooth preferably is aboutthe same across the crown. However, so long as the form and dimensionsof each tooth fulfill the above requirements, and the teeth areotherwise suitably mechanically designed to withstand the physicalstresses of the joining operation, slight variations in height or lengthof a tooth or between teeth are of no significance. The width of eachtooth, however, must be substantially the same in each peripheral row inorder that each tooth will be in shearing relationship with itscorresponding coacting die plate ribs.

The die plate has a plurality of narrow openings, or slots, extendingtangentially adjacent to the roll and spaced in rows along the length ofthe die plate, with the slots corresponding in widths, number andpositions with the widths, number and positions of the correspondingperipheral rows of teeth of the punch roll. The slots must be at leastsufficiently long enough to permit the teeth of the punch roll to rotatefreely through the slots from rear to front during the sheaingoperation. In addition, it is critical that there be sufficientclearance between the rear of each slot and the teeth of the punch inthe corresponding peripheral row so that as a tooth makes a cut into theweb the cut is made with the forward edge and with the sides of thetooth, but not with the rear edge of the tooth. The rear edge of eachtooth preferably is rounded. Moreover, the rear edge of each tooth mustclear the rear of its die slot by a distance essentially at least asgreat as the thickness of the overlapped sheets in a downwardly bentposition. This minimum clearance is necessary in order that the tabswill not be severed from the sheets by the back edge of the tooth. Also,the metal forming the rear ends of the slots must be close enough to theteeth to provide a support for the webs in order that the webs are notbulged, drawn, or crumpled by the teeth during the tab forming step.However, each slot at the rear need be no longer than necessary toprovide a support against which the attached portion of the tabs can bebent by the tooth. Preferably, the rear of each slot is from about 3" to5" back from the vertical center line of a diameter punch roll.

The die plate preferably is made and mounted to the apparatus so that itcan be adjusted forward or rearward to provide the optimum position forsheets of a particular thickness and for sheets of different rigidityand ductility. Each slot at its forward end must be at least long enoughand far enough forward from the teeth in its corresponding peripheralrow to permit the teeth to pass upward freely through the slots fromrear to front when the punch roll rotates. The ribs between adjacentslots must be wide enough to firmly support the overlapped webs as theyare sheared by the teeth of the punch roll. In the embodiment shown inFIGS. 1 and 7, the slots and ribs of the die plate 14 are shown toextend forward beyond the vertical center line of the punch roll 6.However, the die plate at its front end need only have ribs long enoughto provide shearing edges at least long enough for the teeth of thepunch roll to make shearing contact with the edges of the die ribs atthe points of contact of the teeth with the webs and provide support forthe webs.

The width of each slot must be sufficient to permit each correspondingperipheral row of teeth to pass freely through the slot. However, it iscritical that the width of the slot, in relation to the teeth, be suchthat a shearing relationship is established between the teeth and theedges of the ribs of the slot, with the side cutting edges of each toothcooperating with the upper cutting edges of the sides of the ribsbetween each slot to shear cleanly the sides of a set of tabsimmediately after the forward edge of the tabs has been formed by theforward edge of the tooth.

The slots are in the form of openings essentially extending through thedie plate. The openings serve to provide an open space through whichslivers of metal and broken tabs, if any are formed, can freely fall. Inthis form the slots prevent jamming of the die plate and breakage ofpunch roll teeth. This feature of the joiner of this inventionrepresents an important improvement over prior art joiners and resultsin highly eflicient operating of the joiner at previously unattainablespeeds. Moreover, there is no need to shut down for cleanouts, which arecostly in that they hold up an entire production line.

The thickness of the die plate, except for strength, is not critical.Accordingly, the die plate should be sturdy enough to withstand theheavy stresses suddenly placed on it when a shearing operation is madeon sheets passing through the joiner at several hundred feet per minute.Otherwise, its design should be such that the requirements for the slotsand ribs are achieved as detailed above.

The die plate can be made in one piece in which the necessary slots aremachined. Preferably, the die plate is made up of a series of plateseach having vertical side openings machined on the same side. The seriesof plates are then assembled and attached side by side on the supportingstructure of the joiner below the punch roll, with the side openings, inassembled form, corresponding to the slots in the machined plateembodiment. This arrangement is advantageous in that individual platescan be replaced without replacement of the entire die plate.

The forward ends of the slots can be closed and the front end of the dieplate then serves as the tab knockover plate of the tab folding station.Preferably, the forward ends of the slots are left open so that theprojecting tabs can move freely through the slots to a separate tabfolding station. The tab folding station consists of a knockover bar orplate, against which the projecting tabs impinge and are bent and foldedalmost flat against the web. An opposing upper web holddown bar or platecooperates with the knockover bar to hold the webs firmly against theknockover bar during the folding of the tabs. When a separate knockoverbar is used, the latter bar preferably has a plurality of narrowopenings, or slots, open at the rear and closed at the front, extendingtangentially to the roll and spaced in rows along its length, with theslots corresponding in widths, number and positions with the widths,number and positions of the corresponding peripheral rows of teeth ofthe punch roll and the corresponding slots in the die plate. The sidesof the slots serve to guide the sides of the tabs as the tabs are foldedrearward, thus providing means by which the tabs are kept from skewingduring the folding process. This feature is particularly advantageouswhen heavy sheet material is being folded. The closed forward ends ofthe slots, whether in the forward end of the die plate or in a separateknockover bar, preferably are inclined from the bottom to the top of theplate or bar, e.g. at 15 to 60 C., to permit a gradual bending of theoverlapped tabs. The upper web holddown bar also serves as a web releaseplate behind the punch roll.

In still another embodiment, the die plate can be made in the form of anassembly of individual straight-sided plates, each of the width andlength of a die rib and supported at its ends by supports running to theframe. The plates are assembled side by side in parallel positions tothe form of the die plate with the distance between adjacent plates thesame as the width of a slot in-the machined plate. The spaces betweenthe plates serve as the slots. The sides of the plates are provided withcutting edges adjacent the nearest web surface. In this form, the rearsupport to which the plates are mounted also serves to support the uncutportion of the tabs. The front end of each plate can be supported to thebed of the frame of the machine if the opening between the plates is tobe left open, particularly when a separate knockover bar is used. Thefront end of each plate preferably is supported by a support in the formof a knockover bar running to the sides of the frame.

This arrangement is advantageous in that individual plates can bereplaced without replacement of the entire die plate and requires lessmachining than the indented form of plate.

It is to be understood that the term die plate is intended to Includeall forms of the die plates, whether made in one unit or whether made ofan assembly of individual plates.

The pressing station preferably consists of a pair of calendering, orpressing, .rolls both of which can be smooth. Preferably, however, oneof the calender rolls (the one on the same side of the webs as the punchroll) has a plurality of shallow grooves or recesses formed in the rolland extendingperipherally around the roll and spaced in rows along theaxis. The rows of grooves correspond in widths, number and positionswith those of the corresponding peripheral rows of teeth of the punchroll. The depths of the grooves should be suflicient to receive thebulges of metal formed in the top of the webs when the tabs are pressedbetween the other calender roll, which preferably is smooth, and thegrooved calender roll.

When the punch roll and die plate are operating, particularly at highspeeds, the projecting tabs tend to cling to the recesses in the dieplate and particularly the webs tend to cling to the teeth of the punchroll, thu causing a drag on the webs. In order to overcome this clingingand drag it is necessary to have present in the web joiner, immediatelyafter the punch roll and die plate, a web release plate on the side ofthe webs opposite the die plate and preferably immediately opposite theknockover plate. This web release plate has a plurality of slots orspaces corresponding in widths, number and positions to thecorresponding peripheral rows of teeth of the punch roll. The metalbetween the slots forms fingers which serve to pry the webs free fromthe punch teeth. As disclosed above, the upper web holddown plate at thefolding station can be used for this purpose.

In a particularly preferred embodiment, the front web guide plate andthe upper web holddown plate at the folding station are made in the formof a single com'bined unit which is appropriately slotted and curvedfrom rear to front and which passes under the punch roll and over thewebs and thus serves three purposes, i.e., guide plate, web releaseplate and web holddown plate. The slots must be at least wide enough topermit the peripheral rows of teeth to pass through the slots freely,but preferably they are somewhat wider. When using this combinedpurposes plate, the punch r011 preferably is recessed adequately in thespaces between the peripheral rows of teeth along its axis to clear theribs of the plate. Alternately, a thin plate is used and the teeth aremade sufiiciently long to pass through the combined thickness of theplate and webs and into the die plate slots.

The calender rolls preferably are mounted so that the rolls are movablerelative to each other, along the plane of their axes, in order toengage or disengage the plurality of webs. The movement can be done witha combination of cams and springs, or hydraulic pistons, or similarlifting and lowering means acting on one or both roll mountings.

The web joiner machine preferably is provided with a power source fordirectly driving the calender rolls, the source also preferably beingconnected to a clutch means for driving the punch roll. vided forstopping the punch and calender rolls. If desired, particularly in smallsized joiner machines, the punch roll can be provided with its owndrive, brake and control means.

The punch roll teeth preferably are arranged with substantially uniformspacing between teeth along the roll and around the periphery of theroll. The teeth in the rows of teeth along the roll preferably arestaggered slightly relative to the teeth in each adjacent row in orderto minimize the work load on the joiner, thus permitting the teeth ineach row to cut in series rather than all at once.

The total number of teeth is not critical. Sufiicient teeth must,however, be provided to ensure adequate joining, but they should not beso closely spaced together that the webs will be weakened by forming anexcessive number of perforations when the tabs are formed. Thus, on aneight inch diameter punch roll from 4 to 8 teeth equally spaced apartalong about two-thirds of the periphery of each peripheral row andspaced about an equal distance from the closest tooth in an adjacentperipheral row are preferred.

The webs which are to be joined can be of any convenient orconventional, width, e.g. from 2" to 72" in width. The width of thejoiner bed can then be of appropriate size to accommodate the range ofweb widths expected to be encountered. The array of teeth can be spacedaccordingly at any suitable distance, from about 1" to 6" beingpreferred.

The calender rolls normally will be mounted sufficiently apart so thatthe non-tabbed webs will pass freely between them without restriction.Preferably, the calender A brake means is also pro- 6 rolls are mountedso that they can be moved together to engage the webs tightly and assistin pulling them through the web joiner when carrying out the pressingoperation. In many equipment lines, the web driving means in othersections of the line will be adequate for pulling purposes.

The Web joiner is preferably provided with electrical and pneumaticmeans for automatically controlling the web joiner in carrying out thesplicing operation. The control means preferably cause the calenderrolls to close and open at predetermined times. They also cause thepunch roll to revolve a predetermined number of revolutions andessentially to stop with the punch roll in standby position, i.e. withthe non-toothed surface of the roll opposite the web surfaces. Thisprocedure is necessary in order that the web passing through the joinerduring a non-joining phase is not damaged by the teeth of the punchroll. Preferably, the control means are automatically activated, e.g.,.by electronic means actuated by the tail end of the first web. Forvexample, colored markings can be painted on at least one edge or side ofthe last to feet of the tail section of the first web. As the firstportion of this section passes an electronic color sensing means, thecontrol means hereinafter described are first activated, and when theend of the tail section approaches, are then stopped. At comparativelylow speeds, the control means can be manually activated by an operator.

The webs are fed into the web joined from a supply station, e.g. a pairof rolls on a roll stand. As one roll of web is about to expire, theleading end of the second roll of web is positioned in the web joiner onthe same side as the punch roll. For example, if thepunch roll is ontop, as is shown in FIG. 1, the second web 98a is placed on top of theweb 98 which is expiring.

A guide table (no-t shown) is used to align the webs laterally. As theweb leaves the joiner, it is processed as desired in the treating lineand is taken up on rolls or otherwise disposed of beyond the web joinermachine.

Webs which are joined in the web joiner can be any rolled thin metalplate or strip. However, the webs can also be sheets, plates or stripsof other materials which are foldable, such as coated papers andfabrics, woven materials, synthetic plastics and so on.

The invention can be under-stood best from a detailed description of apreferred embodiment of the invention, selected for purposes ofillustration and shown in the accompanying drawings, in which:

FIG. 1 is a perspective and somewhat exploded view of the elements ofthe web joiner in operating position with the supporting frame structureand electrical and pneumatic controls removed for clarity.

FIG. 2 is a cross-sectional schematic diagram showing the punch roll anddie plate in pre-cutting position.

FIG. 3 is a cross-sectional schematic diagram showing the punch roll anddie plate in cutting position during the first cut.

FIG. 4 is a cross-sectional schematic diagram showing the punch roll anddie plate in cutting position near the end of the first revolution,after several cuts have been made, and with cut tabs in various stagesof folding and pressing.

FIG. 5 is a combined electrical and pneumatic operating flow diagram.

FIG. 6 is a partial cutaway and cross-sectional view taken along thelines 6-6 of FIG. 3.

FIG. 7 is an enlarged view of the portion enclosed in the dashedtriangle in FIG. 4.

FIG. 8 is an enlarged view of the portion enclosed in the dashedrectangle in FIG. 4.

FIG. 9 is an enlarged view of the pressed tab 88 of FIG. I viewed fromabove.

FIGS. 10, 10a and 10b are plan, elevation and side views, respectively,of a combined web guide, web release and Web holddown plate.

FIGS. 11, 11a and 11b are plan, elevation and side views, respectively,of a die plate made up of a series of indented rib plates assembled inthe form of the die plate of FIG. 1.

FIG. 12 is a fragment of a plan view of a die plate composed of a seriesof indented rib plates assembled in the form of the die plate of FIG. 11and having the forward end of each rib plate closed to form a knockoverbar portion.

FIG. 13 is a fragment of a plan view of a combined die plate andknock-over bar in the form of the die plate of FIG. 1 and having theforward ends of the slots closed substantially in the form of theknockover plate of FIG. 1.

FIG. 14 is a cross-sectional schematic diagram showing the punch rolland die plate in cutting position and in which the combined web guide,web release and web holddown plate of FIG. is used in combination withthe combined die plate and knock-over plate of FIG. 13, and in furthercombination with a pair of opposed flat pressing plates.

Referring to FIG. 1, there are a pair of spaced supporting frame plates2 and 4 with their center, end and lower sections broken away forclarity. These plates support the following elements: a punch roll 6which is fixedly mounted on shaft 8, which rotates within bearing 10 setin mounting block 12; a die plate 14 which is adjustably attached to andsupported on supports 14a, which are attached to plates 2 and 4; anupper calender roll 22 which is fixedly mounted on shaft 24, whichrotates within bearing 26 set in mounting block 28; a lower calenderroll 30 which is fixedly mounted on shaft 32, which rotates withinbearing 34 set in mounting block 36; a pair of forward guide rolls 38and 40 fixedly mounted on shafts 42 and 44, which rotate within bearings46 and 48, respectively; a rear guide roll 50 which is fixedly mountedon shaft 52, which rotates within bearing 54; an upper web release andholddown plate 56; a tab knockover plate 58; a front web guide plate56a; a pair of supports 60 for calender roll depressing rod 60; a camshaft 62, supported at its ends by bearings 108 in frames 2 and 4; andan air cylinder assembly 64 which has its lower end fastened to theframe 2 and a hinged piston arm 66 securely fastened at its extreme endto cam shaft 62.

The punch roll 6 preferably comprises an assembly of a plurality ofspacers 70 alternatingly arranged and keyed axially on shaft 8 with aplurality of axially spaced punch disks 72. Each punch disk 72 has aplurality of cutting teeth 74 arranged as heretofore described.

The die plate 14 preferably comprises a plurality of ribs 76 withcutting edges 76a arranged between a plurality of slots 78 correspondingin widths, number and positions to the plurality of corresponding punchdisks 72, said die slots being arranged to permit the side edges ofpunch teeth 74 to move freely through the slots 78 in shearingrelationship with cutting edges 76a as roll 6 rotates, as shown in FIGS.2, 3, 4 and 6.

The front web guide plate 56a comprises a plurality of ribs 59 and ofopen-ended slots 59a corresponding in widths, number and positions tothe plurality of corresponding punch disks 72.

The upper web release and holddown plate 56 has a plurality of slots 80likewise corresponding in widths, number and positions to the pluralityof punch disks 72.

The tab knockover plate 58 also has a plurality of slots 82corresponding in widths, number and positions to the plurality of punchdisks 72.

The plates 56 and 58 are formed at the ends of slots 7 80 and 82,respectively, substantially as shown in FIG. 7 at 84 and 86.

The upper calender roll 22 is preferably made in one piece and has aplurality of machined recesses 90 corresponding in widths, number andpositions to the plurality of corresponding punch disks 72, saidrecesses being sufiicient to receive the excess of metal bulge formedduring the calendering step, as is shown in FIG. 8 at 88.

The lower calender roll 30 preferably also is made in one piece and issmooth.

Cam shaft 62 has rigidly attached to it a pair of cams 92 which arearranged to engage a pair of calender roll depressing rods 94. A pair oftension springs 96 are arranged on rods 94 between supports 60 andmounting blocks 28 on calender roll 22.

The roll 6 is mounted in the supporting frames 2 and 4 with the mountingblocks 12 secured in a fixed but adjustable position relative tomounting block 20 which supports bearing 18 and driveshaft 16. The punchroll 6 and the die plate 14- are normally spaced apart as shown in FIG.6 with sufficient space between the rolls to permit at least twothicknesses of web 98 to move freely between the rolls.

Each punch disk 72 has a plurality of cutting teeth 74 arranged part wayaround the circumference of the disk substantially as shown in FIGS. 2,3 and 4. The teeth 74 are substantially equally spaced along the toothedsection of the circumference and along the roll. The plurality of disks72 is assembled along with the plurality of spacers 70 on shaft 8 and isappropriately locked on the shaft 8 by keying means so that the teeth 74form rows along the axis of shaft 8 substantially in a slightlystaggered line along the roll. The teeth preferably do not form astraight line along the roll. However, it is essential that when punchroll 6 is in a nonoperating state, the webs 98 and 98a pass freelybetween roll 6 and die plate 14.

The tab knockover plate 58 is adjustably mounted in a fixed positionwith its ends supported by frames 2 and 4. Plate 58 is positioned withits upper surface in the same plane as and level with the upper surfaceof die plate 14. Plate 58 is further positioned so that the ribs 102 andthe slots 82 are in close operating position with die plate 14, as shownin FIG. 7.

The upper web release and holddown plate 56 is adjustably mounted in afixed position with its ends supported by frames 2 and 4. Plate 56 ispositioned with its lower surface in the same plane as and level withthe lower surface of punch roll 6. Plate 56 is further positioned sothat the slots and web release fingers 109 are in close Web releasingposition with punch roll 6, as shown in FIG. 7.

The lower calender roll 30 is mounted in the supporting frames 2 and 4with the mounting blocks 36 secured in a fixed position. The uppersurface of roll 30 is positioned at the same plane as and level withthat of die plate 14.

The upper calender roll 22 is mounted so that it is vertically movablein the supporting frames 2 and 4, with the sides of mounting blocks 28vertically guided within a guide framework, not shown, in frames 2 and4. The bottoms of blocks 28 rest on springs 106 which tend to urge andhold the assembled upper calender roll 30 upwardly in opposition tosprings 96 when roll 30 is in a nonoperating state.

Cam shaft 62 is mounted rotatably by its ends in bearings 108 in thesupporting frames 2 and 4. Hinged piston arm 66 is adjustably attachedat one end to cam shaft 62 and is positioned to simultaneously rotatethe cam shaft 62 and cams 92 in an arc sufiicient to move the cams 92from a nonpressing position when calender roll 22 is in a raised,nonoperating state to a lowered, pressing position when calender roll 22is placed in operating state.

Guide rolls 38, 40 and 50 are mounted by their shaft ends and bearingsin the supporting frames 2 and 4. The lower forward guide roll 40 ispositioned so that its top is in the same plane as and level with thatof the top of die plate 14. Upper guide rolls 38 and 50 are positionedso that their lower sides are in the same plane as and level with thatof punch roll 6.

The web joiner is provided with a motor 132, FIG. 1, which drivesflywheel 136 by means of belt 134. Shaft 142 is directly driven byflywheel 136 and directly turns gear 110 in a counterclockwisedirection. Gear 118 meshes into gear 122 causing lower calender 30 andgear 128 to turn clockwise. Gear 128 causes gear 130 and the uppercalender roll 22 to turn counterclockwise.

A clutch mechanism 138 and a brake mechanism 140 are provided and aremounted on a hollow shaft 145 supported by bearings 149 and passing overshaft 142. A drive drum 143 is provided and is revolvably mounted aroundthe clutch 138. The drum is fixedly mounted on the flywheel side toshaft 142. A clutch band 139 is provided for causing the drive drum 143to actuate the clutch 138 and to turn brake mechanism 140' and gear 147counterclockwise. Gear 147 turns gear 120, which causes gears 112 and114 to turn counterclockwise and gear 116, shaft 16 and gear 124 to turnclockwise. Gear 124 causes gear 126 and punch roll 6 to turncounterclockwise. The train of gears 147, 121 112, 114, 116, 124 and 126are designed so that one revolution of gear 147 causes one revolution ofgear 26 and the punch roll 6.

The brake mechanism 140 is provided with a brake drum housing 151 and abrake band 141. The housing is fixedly mounted to the frame 4.

Referring to FIGS. 2, 3 and 4, 72 is a punch disk on punch roll 6; 74 isone of the plurality of punch teeth, of which five are shown in thepresent embodiment; 101) is the non-toothed section between the teeth 74on disk 72; 98a is the second or upper sheet; 98 is the first or lowersheet; 56 is the upper web release and holddown plate; 56a is the frontweb guide plate; 58 is the tab knockover plate; 76 is a rib; 78 is aslot; 22 is the upper calender roll; 90 is a machined recess in roll 22;30 is the lower calender roll; and 8, 16, 24 and 32 are shafts. In FIGS.3 and 4, 98b are tabs.

Referring to FIG. 5, 1 is a airflow control valve in which an airflowdirecting core 3 is actuated upwardly by solenoid switch 5 (the core isshown in an actuated position); 3a is an air passage; 3b is an exhaustline from valve 1; 7 is an air valve to airflow control cylinder 9; 11is a solenoid switch to which valve piston 13 is attached by means ofrod 15; 64 is the air cylinder assembly of FIG. 1 in which piston 17moves within cylinder 19 to advance and retract piston arm 66; 23 is anairflow control cylinder; 25 is a piston which is mounted on pistonguide rod 27 and which is moved to an advanced position (shown) whensolenoid switch 29 is actuated and which is moved to a retractedposition (dotted) when solenoid switch 31 is actuated; 138 is theclutch; 140 is the brake; 142 is the drive shaft from motor 132 to gear110 which drives the calender rolls 22 and 30 of FIG. 1; 143 is thedrive drum; 139 is the clutch band; 151 is the brake drum housing; 141is the brake band; 145 is the hollow shaft to gear 147 which drives thepunch roll 6 and shaft 16 33 is a contact arm on shaft 145; 132 is theelectric motor; 35 is a master start-stop switch; 37 is an electricalrelay switch; 39 is a cycle selector switch; 41 is a cycle limit switch;43 is an electrical cycle counting relay switch;

45 is a limit switch; 47 is a limit switch; 49 is an operating cyclestarting switch; 51 is an electrical lock-in relay switch; 81 is alock-in relay line from switch 51 to line 57; 53 is an air bleedervalve; 55, 55a, 55b, 55c, 55d, 55a, 55 and 55g are air lines; and 57,59, 61, 63, 65, 67, 69, 71, 73, 75, 77, 79 and 81 are electrical lines.

Referring to FIG. 6, 6 is the punch roll; 14 is the die plate; 70s arespacers; 72 is a punch disk; 74 is a punch tooth; 76s are die plateribs; 98a is the second or upper sheet; 98 is the first or lower sheet;and 98b is a lower tab. The cutting edges are 76a, and 78 is a slot indie plate 14.

Referring to FIG. 7, 14 is the die plate; 14b are the surfaces againstwhich the webs are supported during the shearing of the tabs; 72 is thepunch disk; 74 is a tooth on punch disk 72; 74a is tooth 74 inpre-cutting position; 74b is the crown of tooth 74; 76 is the die platerib; 76a is the shearing edge of die plate rib 76; 56 is the upper webrelease and holddown plate; 58 is the knockover plate; 104 is a rib ofthe upper web release and holddown plate 56; 182 is a rib of theknockover plate 58; 84 is the back edge of recess 80 in the upper webrelease and holddown plate 56 shown in FIG. 1; 86 is the back andfoldover edge of recess 82 in the knockover plate 58 shown in FIG. 1;98b are tabs; 980 are slots left where tabs 98b were cut; and 98d is theapproximate point at which the front edges of the tabs 98b are sheared.

Referring to FIG. 8, 22 is the upper calender roll shown in FIG. 1; 38is the lower calender roll shown in FIG. 1; is a machined recess in roll22; 98a is the second or u per sheet; 98 is the first or lower sheet; 88is a calendered tab body; 98b are tabs; and 980 are slots left wheretabs 98b were cut out.

Referring to FIG. 9, 98 is the first or lower sheet; 980 is the secondor upper sheet; 980 is a slot; and 88 is a calendered tab body.

Referring to FIGS. 10, 10a and 10b, 56b are the holddown portion of thecombined web guide, web release and web holddown means 10911; 560 areside supports for 109a which mount to frames 2 and 4 of FIG. 1; 59 arerib plates between slots 80a, which slots correspond to slots 80 of FIG.1; and 84b are back edges of slots 88a corresponding to back edge 84 ofFIG. 7.

Referring to FIGS. 11, 11a and 11b, 14a are side sup ports for the dieplate assembly 14b which mount to frames 2 and 4 of FIG. 1; 14c. aresupport surfaces for webs 98 and 98a of FIG. 1; 14g are cross-supportsfor die rib plates 76b which correspond to die rib plates 76 of FIG. 1;14d are mounts screws for (lie plate ribs 76b; 76a are cutting edges ofdie plate ribs 76b; and 78a are slots corresponding to slots 78 of FIG.1.

Referring to FIG. 1'2, 14:: is a combined die plate and knockover platecorresponding to die plate 14 of FIG. 1 and die plate 14b of FIG. 11;14a is a support for the combined plate 142 which mounts to frame 4 ofFIG. 1; 14c are support surfaces for webs 98 and 98a of FIG. 1; 76a arecutting edges corresponding to cutting edges 76a of FIG. 1; 760 is a dierib plate corresponding to die rib plate 76b of FIG. 11; 78a is a dieslot corresponding to slot 78 of FIG. 1; and 86a is a back and foldoveredge corresponding to edge 86 of FIG. 7.

Referring to FIG. 13, 14 is a combined die plate and knockover platecorresponding to die plate 14 and knockover plate 58 of FIG. 1; 14a is asupport for the combined plate 14 which mounts to frame 4 of FIG. 1; 140are support surfaces. for webs 98 and 98a of FIG. 1; 76a are cuttingedges corresponding to cutting edges 76a of FIG. 1; 78a is a die slotcorresponding to slot 78 of FIG. 1; and 86a is a back and foldover edgecorresponding to the edge 86 of FIG. 7.

Referring to FIG. 14, 6 is the punch roll; 8 is a shaft; 72 is a punchdisk; 74 is a tooth; 74b is the crown of tooth 74; 100 is thenon-toothed section of punch roll 6; 56b is the holddown portion of thecombined web guide, web release and web holddown means 109a, shown indetail in FIGS. 10, 10a and 10b; 59 is a rib plate; is a support surfacefor webs 98 and 98a; 14 is a combined die plate and knockover platecorresponding to that of FIG. 13; 76b is a die plate rib; 76c is thecutting edge of said rib; 78a is a slot adjacent said rib; 86a is afoldover edge; 98b are tabs; 560 is an upper web holddown and pressingplate; 58b is a lower pressing plate; 80a is a slot; 84a is the backedge of slot 80a; and 86b is a sloped bottom edge of slot 1112a.

The upper web holddown and pressing plate 560 is shown in FIG. 14 ashaving a solid cross-section running forward from the back edge 84a ofslot 80a. In another embodiment, the bottom of plate 56c can be made ina grooved form with grooves similar to grooves 90 of upper calender roll22, and serving the same purpose, running from the right end of slot 80aforward to the front, or right, end of plate 560 as viewed in FIG. 14.

Operation of the web joiner in a joining operation will now bedescribed. Prior to the joining operation, sheet 98, FIG. 1, is movingfreely through the web joiner and resting lightly, if at all, on roll40, die plate 14, and roll 30. The punch roll 6 is in rest position withthe cutting disks 72 FIG. 1 in the position shown in FIG. 2, i.e. withthe non-toothed section 180 of each disk 72 opposite web 98a and withteeth 74 in non-engaging position above web 98a. Calender rolls 30 and32 FIG. 1 are preferably also at rest position, i.e. none are beingdriven. As sheet 98 nears its end, the operator of the web joinerpositions a second sheet 98a FIG. 1 on top of the first sheet 98, FIG. 1by threading the leading edge of sheet 98a first between rolls 40 and38; then under front web guide plate 56a and between the punch roll 6and die plate 14; then between web release and holddown plate 56 and tabknockover plate 58; and then placing the edge of the sheet 98a slightlypast the vertical center line of calender rolls 22 and 30, all as shownin FIG. 1 and FIG. 2. The sheets are held in lateral alignment by guidesnot shown.

Next, in accordance with the electrical and pneumatic control diagramset out in FIG. 5, the operator initially sets cycle selector switch 39to a desired cycling program under which punch roll 6 FIG. 1 will make 1or more complete revolutions, always stopping the punch roll 6 in aposition as shown in FIG. 2, so that no punch teeth are in position tocontact and possibly damage the moving sheet after each cycle iscompleted. The number of revolutions made by the punch roll 6 should beadequate to ensure tight joining in an aligned position of sheets 98 and98a FIG. 1. From 2 to 10 revolutions will usually be suflicient,although more can be used. From 4 to 8 revolutions are preferably used.For purposes of illustration, it will be assumed that the operator setsselector switch 39 for 2 revolutions. The punch roll, having teeth partway around its circumference on each of the seven disks shown in FIG. 1,then is limited to making a total of 70 perforations and sets of tabs.

Having rechecked the position of sheet 98a relative to sheet 98 FIG. 2,the operator then starts electric motor 132 FIG. 5 by placing masterstart-stop switch 35 in start position. Operating cycle starting switch49 is simultaneously placed in ready position by switch 35 throughelectrical line 57. As motor 132 starts, flywheel 136, shaft 142, gears110, 122, 128 and 130 and calender rolls 22 and 30 all begin turning aninstantaneous tangential speed equal to the lineal speed of web 98. Theoperator then places switch 49 in operating position. Lock-in relayswitch 51 holds the cycle operating circuit in energized conditionthrough lines 81 and 57.

Simultaneously solenoid switch 5 is actuated, raising core 3 of airflowcontrol valve 1 into operating position as shown in FIG. 5, with exhaustline 3b positioned in line with air line 55g. At the same time, solenoidswitch 11 is actuated and through rod 15 moves valve spool 13 fromposition 13a in airflow control cylinder 9 to the position shown in FIG.5. Air under a pressure of 60-125 lbs. gauge enters cylinder 9 from airsupply line 55. The air pressure passes through air line 55b into aircylinder 19. The air pressure acts upon piston 17 moving it fromposition 17a to the position shown in FIG, 5. Piston rod 66 which isconnected to piston 17 is simultaneously moved to contact position withlimit switch 47. Also, as may be better seen in FIG. 1, the hinged armof piston rod 66 rotates cam shaft 62 counterclockwise causing eccentriccams 92 to press against rods 94 and to move upper calender roll 22downward against springs 106 to a preset position firmly pressing sheets98 and 98a between calender rolls 22 and 30. Sheet 98 continues to moverapidly through the web joiner. Sheet 98a, however, due to slippage,moves hardly at all.

As piston rod 66 contacts limit switch 47, solenoid switch 29 isactuated through line 61, causing piston 25 to move along rod 27 incylinder 23 from position 25a to the position shown in FIG. 5. Airpressure from line 55 enters cylinder 23 and passes through air line 550into the clutch 138, actuating the clutch band 139 against drive drum143, causing shaft 145 to rotate counterclockwise.

Referring now to FIG. 1, rotation of shaft 145 causes rotation of thebrake mechanism 140. It also causes gear 147 to turn, placing inoperation gears 128, 112, 114, 116, 124, 126. With the gears inoperation, shaft 16 turns clockwise and punch roll 6 turnscounterclockwise with an instantaneous tangential speed equal to thelineal speed of web 98. The punch teeth 74 begin perforating the sheetsand forming the tabs in cooperation with the die plate 14. Sheets 98 and98a are pulled through the web joiner by the combination of forcesexerted from the pressure from the upper calender roll upon the lowercalender roll and the pulling force created by the punch teeth informing the tabs. When the first set of tabs has been cut, folded backand calendered, the pull of the treating line equipment is additionallyexerted on the joined sheets.

Referring now again to FIG. 5, as shaft 145 rotates, contact arm 33contacts the arm of cycle counting relay switch 43. When the shaft 145,to which gear 147 is directly attached, completes the first of itspreset cycle of 2 turn (illustrative cycle), relay switch 43 actuatescycle limit switch 39 through line 75. Switch 39 counts with the relayswitch 43, turning its contacts through the preset number of shaftrotations. As the last cycle is completed and the shaft 145 completesits 2nd rotation, switch 39 actuates solenoid switch 41 through line 73.Switch 41 actuates solenoid switch 31 through line 65 causing piston 25to move along rod 27 to position 25a in piston 23. Air pressure then isvented from line 550 by an exhaust vent not shown releasing clutch band139. Air pressure is simultaneously applied through line 55d to brake140, actuating the brake band 141 against brake drum housing 151, andcausing shaft 145 to stop rotation at once in a preset position. Thisstops rotation of the punch roll 6 in its proper position as shown inFIG. 2.

Meanwhile, switch 41 also actuates relay switch 37 through line 59.Switch 37 through line 71 throws startstop switch 35 into stop position,turning off motor 132 through line 69. The calender rolls 22 and 30continue to roll briefly under inertia. As switch 35 goes into stopposition, flow of electricity is cut off in line 57, turning olf switch49. With switch 49 turned off, switches 11 and 5 are also deactivated.Piston 13 is then free to move back to position 13a in cylinder 9. Withswitch 5 turned off, core 3 moves down, permitting passage 3a to alignitself with air lines 55 and 55g. Air pressure from line 55 passesthrough line 55a into air bleeder valve 53 and then through line 55 airpassage 3a and line 55g into air valve 7. From air valve 7 the airpressure enters cylinder 9, forcing piston 13 to position 13a, thusshutting 01f direct air pressure from line 55 to air cylinder 9 anddirecting air pressure through line 55a into cylinder 19 to force piston17 into position 17a. An air vent, not shown, relieves backpressure inthe air cylinders 9 and 19.

As piston 17 moves to position 17a, piston rod 66 is retracted. Thiscauses cam shaft 62 and earns 92 to rotate clockwise, releasing thepressure on rods 94, permitting springs 106 to raise the upper calenderroll 22 from contact with sheet 9811. See FIG. 1.

Also, as piston rod 66 retracts, it resets switch 47. Then as thecontact on piston rod 66 moves over limit switch 45, it actuates switch45 through line 63 to energize cycle counting relay switch 43 into areset position.

The web joiner is then ready for the next joining operation.

The air pressure from line 55 continues to be applied to brake band 141through air cylinder 23 and line 55d until the piston 25' again movesfrom position 25a to the posi- 13 tion shown in FIG. 5. This preventsthe punch roll 6 of the web joiner from being moved from the positionshown in FIG. 2, with the teeth 74 of punch roll 6 clearing the sheet98a.

The perforating and pressing operation may be best understood byreferring to FIGS. 2, 3, 4, 6, 7, 8 and 9.

FIG. 2 shows the cutting disk 72 of the punch roll 6 at the start of acutting cycle. FIG. 3 shows the double thickness of sheets 98 and 98abeing pierced by cutting tooth 74 of cutting disk 72 with the tab 98bextending into slot 78 and bent down on the shoulder at the junction ofrib 76 and slot 78.

The piercing or cutting step is better shown in FIG. 6, taken along thelines 66 of FIG, 3, and in FIG. 7. The cutting tooth 74 is shown cuttingthrough sheets 98a and 98 on three sides, bending tabs 98b down intoslot 7 between ribs 76.

FIG. 4 shows the fifth set of tabs 98b being cut by tooth 74 of cuttingdisk 72. It shows the fourth set of tabs 98b in the process of beingfolded back by the knockover plate 58.

The cutting and folding steps can be more clearly understood byreferring to FIG. 7. In FIG. 7, at the left, 74a depicts tooth 74 at thestart of the shearing step in which the tabs 98b are formed. As disk 72rotates counterclockwise and the webs 98 and 98a move linearly from leftto right through the joiner, with the webs supported on die plate 14 bysupporting surfaces 14b, the front edge of tooth 74 pierces webs 98a and98, respectively, when the webs are about at position 98d, forming thefront edges of tabs 98b. The sides of tooth 74 then continue shearingwebs 98a and 98 in cooperation with cutting edges 76a of die plate 14,while the webs move linearly through the joiner at the same lineal speedas the tangential speed of disk 72. As tooth 74 passes through webs 98aand 98, the crown of the tooth 74b gradually forces tabs 98b to adownwardly projecting position, as shown. Tooth 74 then continues itspassage from rear to front through and out of slot 78. Ribs 102 and 109release sheets 98 and 98a from contact with punch roll 6 and disk 72thus freeing the tabs 98b. Tabs 98b then move into slot 82. As thesheets 98 and 98a advance against the knockover plate 58, the tabs 98bimpinge against the foldover edge 86 and are folded rearward. The upperweb release and holddown plate 56 and the knockover plate 58 are eachadjustable and are set so that the folded tabs 98b can passsubstantially unrestricted between the two plates. In FIG. 7, 98c areslots in the sides of sheets 98 and 98a, showing where the tabs havebeen cut away.

Referring again now to FIG. 4, the third set of tabs 98b is shown midwaybetween the plates 56 and 58 and the calender rolls 22 and 3. As can beseen, the tabs are not yet completely pressed against the bottom ofsheet 98. The completion of the pressing takes place between thecalender rolls 22 and 30. As can be seen, the tabs are tabs 98b is shownbeing pressed.

This latter step can be better understood from FIG. 8 where the tabs9817 are shown being pressed between the smooth surface of lowercalender roll 30 and the recess 99 of upper calender roll 22. The excessof metal from the tabs 98b is thus pressed into the surface of sheets 98and 98a, making the lower surface of sheet 98 substantially smooth andfree of ridges which might unduly lift the joined sheet as it passesthrough a subsequent treating line. Sheets 98 and 98a are shown to betightly pressed together and in effect moving as a unit.

Referring again to FIG. 4, the folded over, calendered first set of tabs88 is shown to the right of the calender rolls 22 and 30.

FIG. 9 shows the plan view of one set of tabs 88 and the opening 980where the tabs have been cut from sheets 98 and 98a.

White the punch roll 6 and calender roll 22 have been shown on the upperpart of the joiner and the die plate 14 and calenderroll 30 on thebottom part, the rolls and die plate can be transposed so that the punchroll 6 and calender roll 22 are on the bottom and roll 30 and the dieplate are on top. The positions of plates 56 and 58 should then beinterchanged so that the knockover plate 58 is on top. Then sheet 98awould be fed into the web joiner underneath sheet 98. The tabs 98b wouldthen be cut from the bottom of the sheets and folded upward and rearwardand be calendered substantially as already described. This arrangementand method of operation of the web joiner may be preferred for certainoperations where it is more convenient to feed the second sheet 98a fromunderneath sheet 98.

Also, to facilitate maintenance and inspection of the punch roll 6 anddie plate 14, means, e.g. springs and cams such as are used with thecalender rolls or hydraulic pistons, can be provided for readilyreleasing and raising punch roll 6 so that access can be had to thespace between roll 6 and die plate 14, e.g. in the event that thecutting edges 76a require sharpening. For example, sets of springs canbe placed between bearing blocks 12 and 20 which will raise roll 6 whenbearing blocks 12 are unlocked from position in frames 2 and 4.

Also, although roll 6 has been disclosed as being made up of. aplurality of spacers and disks, the roll can be made in one piece. Forexample, the punch roll 6 can be made of one piece into which cuttingteeth 74 are individually inserted as by screwing, wedging, welding, orlocking into place with bolts.

The joining operation, for pulling purposes, is substantially completewhen the tabs 93b have been folded back between the plates 56 and 58since the pulling forward of the lower sheet 98 necessarily will pullalong upper sheet 98a. Nevertheless, the pressing step is essential in ahigh speed line in order to prevent the sheets from pulling apartthrough whiplash or under inertia in the event that the forward sectionof the treating line is suddenly slowed down before the rear section isslowed.

When joining easily folded materials such as light gauge aluminum orcopper, the pressing step can sometimes be carried out by use of one ormore knockover plates 58 spaced at successively closer settings incooperation with one or more upper web holddown plates 56, so that thefinal setting is about equal to that between the calender rolls duringthe pressing step. The calendering rolls then would not be necessary.However, in such an embodiment where the calender rolls are not used,means may need to be provided to move the sheets 98 and 98a through theweb joiner. In most cases the treating line will cause sufficientmovement of the sheet 98 so that no auxiliary means will be needed. Ifthe line is not able to move the sheets 98 and 98a sufliciently, a setof drive rolls similar to the calender rolls 22 and 30 can be used inconjunction with the web joiner. However, in the latter case, the upperroll would not need to be recessed nor would the rolls need to act ascalenders, provided a sufficient number of knockover plates were used toensure a secure joint, i.e. one which will not pull apart in event ofwhiplash or inertia.

It is intended to cover all changes and modifications of this inventionsubstantially as disclosed herein including such changes which do notdepart from the spirit and scope thereof. The invention can be used tojoin dissimilar materials as well as similar materials. Also, it can beused to join more than one new web to a preceding web or plurality ofwebs by overlapping the leading ends of the new webs upon each other andthe tail end or ends of the preceding web or webs, up to the capacity ofthe punch roll to cut, the tab bending station to bend and the pressingstation to press the multiplicity of tabs. Furthermore, webs ofdifferent thicknesses can be spliced together by the web joiner. Whilethe joiner is intended principally for use in connection with metaltreating lines, it can also be used in other fields of services, such asprinting, laminating, strip forming and the like, i.e. wherever it isadvantageous to join the leading end of a roll of material to the tailend of a preceding roll under continuous operating conditions.

What is claimed is:

1. In a machine for joining in overlapping relationship a plurality ofoverlapped webs of foldable material, at least one of said websinitially being substantially stationary and at least one of said websinitially moving linearly through said machine at high speed relative tothe bed of the machine, comprising tab cutting means for producing insaid overlapped webs a plurality of partial perforations with projectingtabs retained adjacent said perforations at the rear of saidperforations relative to the direction of movement of the webs;

tab folding means for acting upon said projecting tabs to fold themrearward from said direction of movement;

tab pressing means for pressing said tabs against said webs; theimprovement wherein said tab cutting means consists essentially of apunch roll supported at its ends by the frame of said machine andadjacent to one of the flat surfaces of the webs and having a pluralityof substantially hexahedral teeth projecting from its surface and spacedin staggered rows extending along the roll and spaced in alignedperipheral rows in a toothed section extending part away around theperiphery of the roll,

with an essentially non-toothed section in the remaining part of theperiphery of each peripheral row, said non-toothed sections essentiallybeing aligned relative to each other along the roll so that no tooth inthe roll contacts the webs when the center line along the roll of thecomposite arcuate surface of said sections is opposite said webs, saidteeth each having forward and side cutting edges and a non-cuttingrearward edge; and a die plate substantially coplanar with the flatsurfaces of said webs and adjacent thereto on the opposite side of saidwebs and opposite said punch roll and having parallel alternating slotsand ribs running from front to rear of said plate with cutting edgesalong the sides of said ribs opposite the side cutting edges of saidteeth,

said slots corresponding in widths, number and positions to the widths,number and positions of corresponding peripheral rows of said teeth andproviding openings through said die plate, said slots being positionedto permit said peripheral rows of teeth to pass into and out of saidslots from rear to front in shearing relationship with the cutting edgesof said ribs when said punch roll rotates and to permit the die plate atthe rear of the slots to support the rearward portion of the tabs innon-shearing relationship with said teeth; said machine including drivemeans for turning said punch roll codirectionally with said moving weband for providing said roll with an instantaneous tangential velocityequal to the lineal velocity of the moving web, and means for stoppingthe rotation of the punch roll at the end of a predetermined number ofrevolutions when the nontoothed section is opposite a flat surface ofthe joined webs with no tooth contacting said surface.

2. In the machine according to claim 1, a combined guide web release andweb holddown means positioned between the punch roll and the die plateand extending from a position ahead of the roll to a positionsufiiciently after the roll to permit the web holddown portion of saidmeans to cooperate with a knockover means lying in the plane of said dieplate and adjacent thereto, said combined means consisting essentiallyof a slotted plate supported at its side edges by the frame of saidmachine and being closed at its front and rear edges and having aplurality of ribs and slots running from said front to rear edges, saidslots corresponding in number and positions to those of the peripheralrows of teeth on said punch roll and providing openings through saidplate at least sufliciently wide enough to permit said teeth to rotatefreely through the-slots, said plate being sufficiently thin to permitsaid teeth to pass unobstructed simultaneously through said plate and aplurality of webs lying on said die plate and into shearing relationshipwith said die plate.

3. In the machine according to claim 1, a die plate assembly comprisinga plurality of rib plates having cutting edges and assembled to the formof said die plate, said rib plates each consisting of a plate supportedat its front and rear ends by cross supports running to the frame ofsaid machine, each plate having running from front to rear a straightedge and a parallel indented edge, each of said edges having a cuttingedge, each of said indented edges being in the form of a cutawayindentation having the width of a corresponding row of peripheral teethon said punch roll and running from top to bottom of said plate, saidindentation being long enough to permit said teeth to pass into and outof said indentation and having its rearward end positioned to permit thedie plate at the rear of the indentation to support the rearward portionof the tabs in non-shearing relationship with said teeth, each of saidplates being assembled and secured to said cross supports with itsstraight edge immediately adjacent to the indented edge of the nextadjacent plate on one side and with its indented edge immediatelyadjacent to the straight edge of the next adjacent plate on the otherside, said assembled plates pro viding cutting edges having shearingrelationship to the teeth of said punch roll.

4. In the machine according to claim 1, a combined die plate and tabfolding means, said combined means consisting essentially of a die plateaccording to claim 1 wherein the forward ends of the slots are closedthereby forming a tab folding means against which the projecting tabsimpinge and are folded rearwardly during the forward movement of thewebs through the machine.

5. In the machine according to claim 3, a die plate assembly wherein theforward end of each indentation is closed thereby forming a tab foldingmeans against which the projecting tabs impinge and are foldedrearwardly during the forward movement of the webs through the machine.

6. In the machine according to claim 1, combined tab folding and tabpressing means consisting essentially of a plurality of pairs ofstationary opposed plates supported at their ends by the frame of saidmachine and positioned parallel to said punch roll adjacent the surfacesof said webs with one member of .each pair above and the other memberbelow said webs and with each successive pair spaced at progressivelycloser folding and pressing distances relative to the preceding pair.

7. In the machine according to claim 1, a non-toothed section in eachrow of peripheral teeth on the punch roll, said section extending forabout to of the periphery of said row.

8. A machine according to claim 1 in which the die plate is adjustablevertically and horizontally with reference to the positions of the teethin the peripheral rows.

9. A machine according to claim 1 in which the folding means includes aknockover means bearing slots spaced along its length on its tabengaging side, said slots corresponding in widths, number and positionsto the peripheral rows of teeth along said punch roll, and having ribsadjacent and parallel to the sides of said slots, said slots and ribscooperating to guide the sides of the tabs within said slots during thefolding step.

10. A machine according to claim 1 in which the punch roll is verticallyadjustable with reference to the surface of the die plate and the slotsthereof.

11. A machine according to claim 1 in which the drive means are actuatedand stopped by automatic means actuated by a forward portion and arearward portion respectively of the tail section of the moving web asit passes into the machine.

12. In the machine according to claim 2, a combined die plate and tabfolding means, said combined means consisting essentially of a die plateaccording to claim 1 wherein the forward ends of the slots are closedthereby forming a tab folding means against which the projecting tabsimpinge and are folded rearwardly during the forward movement of thewebs through the machine.

13. In the machine according to claim 12, tab pressing means consistingessentially of at least one pair of stationary opposed plates supportedat their ends by the frame of said machine and positioned parallel tosaid punch roll in pressing relationship adjacent the surfaces of saidwebs with one member of a pair above and the other member below said websurfaces and with the distance between said members greater at the tabentering edges than at the tab leaving edges, said distance at the tableaving edges of the last pair being about equal to twice the combinedthickness of the plurality of webs.

References Cited by the Examiner UNITED STATES PATENTS 2,002,554 5/1935Townley 2921.1 2,945,462 7/1960 Obersuer 113-1 3,060,945 10/ 1962 Spenle29-21.1 3,129,489 4/1964 Nelson 29-211 CHARLES W. LANHAM, PrimaryExaminer.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent Noc3,284,873 November 15, 1966 George Ra Noel It is hereby certified thaterror appears in the above numbered patent requiring correction and thatthe said Letters Patent should read as corrected below.

Column 3, line 4, for "sheaing" read shearing column 6, line 28, for"web joined" read web joiner column 13, line 52, for "rolls 22 and 3."read rolls 22 and 30e lines 55 and 56, for "As can be seen, the tabs aretabs 98b is shown being pressed." read In FIG. 4, the second set of tabs98b is shown being pressed, column 15, line 28, for "part away" readpart way Signed and sealed this 12th day of September 1967.

(SEAL) Attest:

ERNEST W. SWIDER EDWARD J. BRENNER Attesting Officer Commissioner ofPatents

1. IN A MACHINE FOR JOINING IN OVERLAPPING RELATIONSHIP A PLURALITY OFOVERLAPPED WEBS OF FOLDABLE MATERIAL, AT LEAST ONE OF SAID WEBSINITIALLY BEING SUBSTANTIALLY STATIONARY AND AT LEAST ONE OF SAID WEBSINITIALLY MOVING LINEARLY THROUGH SAID MACHINE AT HIGH SPEED RELATIVE TOTHE BED OF THE MACHINE, COMPRISING TAB CUTTING MEANS FOR PRODUCING INSAID OVERLAPPED WEBS A PLURALITY OF PARTIAL PERFORATIONS WITH PROJECTINGTABS RETAINED ADJACENT SAID PERFORATIONS AT THE REAR OF SAIDPERFORATIONS RELATIVE TO THE DIRECTION OF MOVEMENT OF THE WEBS; TABFOLDING MEANS FOR ACTING UPON SAID PROJECTION TABS TO FOLD THEM REARWARDFROM SAID DIRECTION OF MOVEMENT; TAB PRESSING MEANS FOR PRESSING SAIDTABS AGAINST SAID WEBS; THE IMPROVEMENT WHEREIN SAID TAB CUTTING MEANSCONSISTS ESSENTIALLY OF A PUNCH ROLL SUPPORTED AT ITS ENDS BY THE FRAMEOF SAID MACHINE AND ADJACENT TO ONE OF THE FLAT SURFACES OF THE WEBS ANDHAVING A PLURALITY OF SUBSTANTIALLY HEXAHEDRAL TEETH PROJECTING FROM ITSSURFACE AND SPACED IN STAGGERED ROWS EXTENDING ALONG THE ROLL AND SPACEDIN ALIGNED PERIPHERAL ROWS IN A TOOTHED SECTION EXTENDING PART WAYAROUND THE PERIPHERY OF THE ROLL, WITH AN ESSENTIALLY NON-TOOTHEDSECTION IN THE REMAINING PART OF THE PERIPHERY OF EACH PERIPHERAL ROW,SAID NON-TOOTHED SECTIONS ESSENTIALLY BEING ALIGNED RELATIVE TO EACHOTHER ALONG THE ROLL SO THAT NO TOOTH IN THE ROLL CONTACTS THE WEBS WHENTHE CENTER LINE ALONG THE ROLL OF THE COMPOSITE ARCUATE SURFACE OF SAIDSECTIONS IS OPPOSITE SAID WEBS, SAID TEETH EACH HAVING FORWARD AND SIDECUTTING EDGES AND A NON-CUTTING REARWARD EDGE; AND A DIE PLATESUBSTANTIALLY COPLANAR WITH THE FLAT SURFACES OF SAID WEBS AND ADJACENTTHERETO ON THE OPPOSITE SIDE OF SAID WEBS AND OPPOSITE SAID PUNCH ROLLAND HAVING PARALLEL ALTERNATING SLOTS AND RIBS RUNNING FROM FRONT TOREAR OF SAID PLATE WITH CUTTING EDGES ALONG THE SIDES OF SAID RIBSOPPOSITE THE SIDE CUTTING EDGES OF SAID TEETH, SAID SLOTS CORRESPONDINGIN WIDTHS, NUMBER AND POSITIONS TO THE WIDTHS, NUMBER AND POSITIONS OFCORRESPONDING PERIPHERAL ROWS OF SAID TEETH AND PROVIDING OPENINGSTHROUGH SAID DIE PLATE, SAID SLOTS BEING POSITIONED TO PERMIT SAIDPERIPHERAL ROWS OF TEETH TO PASS INTO AND OUT OF SAID SLOTS FROM REAR TOFRONT IN SHEARING RELATIONSHIP WITH THE CUTTING EDGES OF SAID RIBS WHENSAID PUNCH ROLL ROTATES AND TO PERMIT THE DIE PLATE AT THE REAR OF THESLOTS TO SUPPORT THE REARWARD PORTION OF THE TABS IN NON-SHEARINGRELATIONSHIP WITH SAID TEETH; SAID MACHINE INCLUDING DRIVE FOR TURNINGSAID PUNCH ROLL CODIRECTIONALLY WITH SAID MOVING WEB AND FOR PROVIDINGSAID ROLL WITH AN INSTANSTANEOUS TANGENTIAL VELOCITY EQUAL TO THE LINEALVELOCITY OF THE MOVING WEB, AND MEANS FOR STOPPING THE ROTATION OF THEPUNCH ROLL AT THE END OF A PREDETERMINED NUMBER OF REVOLUTIONS WHEN THENONTOOTHED SECTION IS OPPOSITE A FLAT SURFACE OF THE JOINED WEBS WITH NOTOOTH CONTACTING SAID SURFACE.